Cast-in process

Abstract

In carrying out a cast-in process, a cast-in insert member is placed into a cast forming cavity in a casting mold, and a casting is conducted. The cast-in insert member has a barrier layer on its non-deposited surface for inhibiting the deposition of a molten metal. During casting, a portion of a molten metal is introduced to a heating chamber on the side of the barrier layer to come into contact with the barrier layer. Thus, the cast-in insert member can be heated not only from the side of its deposited surface, but also from the side of its non-deposited surface, thereby providing an enhanced strength of deposition of the cast-in insert member.

What is claimed is: 
     
       1. A method of producing a casted product made up of a casted part and a cast-in insert member, wherein said cast-in insert member is firmly attached to said casted part by a high strength joint, comprising the steps of: providing a casting mold including a pair of split dies which have at least one cast forming cavity;   providing at least one cast-in insert member, wherein said at least one cast-in insert member has a deposited surface part and a non-deposited surface part;   placing said at least one cast-in insert member into said cast forming cavity of said casting mold; and conducting a casting comprising the steps of: introducing a molten metal toward said deposited surface part of said at least one cast-in insert member and feeding at least part of said molten metal having been introduced toward said deposited surface part to said non-deposited surface part of said at least one cast-in insert member, thereby   heating said at least one cast-in insert member from a side of said deposited surface part and a side of said non-deposited surface part of said at least one cast-in insert member in order to rapidly and sufficiently heat said at least one cast-in insert member so that said high strength joint is formed at an intersection between said deposited surface part of said at least one cast-in insert member and said casted part; and   letting said molten metal cool to harden and form said casted product wherein said at least one cast-in insert member is firmly attached to said casted part by means of said high strength joint.     
     
     
       2. The method as in claim 1, wherein said step of providing a casting mold includes providing a casting mold which has a plurality of cast forming cavities. 
     
     
       3. The method as in claim 2, wherein said step of providing at least one cast-in insert member includes providing a plurality of cast-in insert members. 
     
     
       4. The method as in claim 3, wherein said placing step includes placing said plurality of cast-in members into said plurality of cast forming cavities. 
     
     
       5. The method as in claim 4, wherein said casting step includes forming said casted product with a plurality of high strength joints where said plurality of cast-in members are firmly attached to said casted part. 
     
     
       6. The method as in claim 1, wherein a tin layer is coated on said deposited surface part, said tin layer being used for promoting deposition of said molten metal on said deposited surface part and lowering a temperature of said molten metal in contact with said tin layer thereby to prevent deposition of said at least part of said molten metal from being deposited on said non-deposited surface part. 
     
     
       7. The method as in claim 1, wherein a portion of said at least one cast forming cavity adjacent said deposited surface part of said at least one cast-in member is connected to a space formed surrounding said non-deposited surface part through an elongated passage means. 
     
     
       8. The method as in claim 1, wherein said at least one cast-in insert member has a wall of a non-uniform thickness and wherein a portion of said at least one cast forming cavity adjacent said deposited surface part of said at least one cast-in insert member is connected to a space formed surrounding said non-deposited surface part through a passage means, said passage means being located adjacent a portion of said at least one cast-in insert member having a larger thickness than a remaining portion of said at least one cast-in insert member. 
     
     
       9. The method as in claim 1, wherein said at least part of molten metal hits upon said deposited surface part of said at least one cast-in insert member and then flows to a side of said non-deposited surface part of said at least one cast-in insert member. 
     
     
       10. A method of producing a casted product made up of a casted part and a cast-in insert member, wherein said cast-in insert member is firmly attached to said casted part by a high strength joint, comprising the steps of: providing a casting mold including a pair of split dies which have at least one cast forming cavity;   providing at least one cast-in insert member, wherein said at least one cast-in insert member has deposited surface part and a non-deposited surface part and wherein said at least one cast-in insert member is provided at said non-deposited surface part thereof with a barrier layer for inhibiting deposition of a molten metal to said non-deposited surface part;   placing said at least one cast-in member into said cast forming cavity in said casting mold; and   conducting a casting comprising the steps of: introducing said molten metal toward said deposited surface part of said at least one cast-in insert member and feeding at least part of said molten metal having been introduced toward said deposited surface part to a side of said barrier layer to come into contact with said barrier layer, thereby heating said at least one cast-in insert member from a side of said deposited surface part and a side of said non-deposited surface part of said at least one cast-in insert member in order to rapidly and sufficiently heat said cast-in insert member so that said high strength joint is formed at an intersection between said deposited surface part of said cast-in insert member and said casted product; and   letting said molten metal cool to harden and form said casted product wherein said cast-in insert member is firmly attached to said casted part by means of said high strength joint.     
     
     
       11. The method as in claim 10, wherein said barrier layer is formed using a resin layer coated with sand. 
     
     
       12. The method as in claim 11, wherein said step of providing a casting mold includes providing a casting mold which has a plurality of cast forming cavities. 
     
     
       13. The method as in claim 12, wherein said step of providing at least one cast-in insert member includes providing a plurality of cast-in insert members. 
     
     
       14. The method as in claim 13, wherein said placing step includes placing said plurality of cast-in members into said plurality of cast forming cavities. 
     
     
       15. The method as in claim 14, wherein said casting step includes forming said casted product with a plurality of high strength joints where said plurality of cast-in members are firmly attached to said casted part. 
     
     
       16. The method as in claim 10, wherein said at least part of molten metal hits upon said deposited surface part of said at least one cast-in insert member and then flows to a side of said non-deposited surface part of said at least one cast-in insert member.